Internal assembly for a faucet

ABSTRACT

The invention is an internal assembly for a faucet comprising an independent base portion; a main body portion; a sealing element; at least one discharge element; a handle that an operator actuates to deliver water at a desired temperature through the discharge element; an annulus, and a radial seal. The main body portion includes a lower disk. The lower disk has a cold water inlet, a hot water inlet and a mixed water outlet. An intermediate disk is positioned adjacent the lower disk. The intermediate disk has a recessed mixing cavity, and further has a dual lobe sealing element to provide the mixing cavity with an arcuate configuration. An upper disk is positioned adjacent to the intermediate disk, and has a central aperture and at least one engaging member that operably couples the upper disk to the intermediate disk. A seat is positioned adjacent the upper disk, and the seat has a central opening. A post and a fixing element, including a flange and an opening, receive a portion of the actuator ball of a joystick, and facilitate operable connection of the joystick with the upper disk. A joystick having a shaft extends through the seat opening, and through the main body. The joystick has a depending actuator that is received in the upper disk aperture to operably connect the joystick to the upper disk. Actuation of the joystick results in movement of the upper disk and intermediate disk, to vary the position of the mixing cavity relative to the hot and cold water inlets.

CROSS-REFERENCE TO RELATED APPLICATION

N/A

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

N/A

FIELD OF THE INVENTION

The invention relates to an internal assembly for a faucet in which mixed water may discharge directly from the assembly.

BACKGROUND OF THE INVENTION

Single handle water faucets suitable for commercial and residential use are well-known. These faucets typically include, for example, a base plate, an upwardly extending main body portion, a discharge segment or spout, and a centrally located handle. A mixing valve or cartridge is positioned within the main body, and includes a vertically extending joystick that is operably connected to the handle. A hot water line or conduit is connected to a hot water inlet of the cartridge, and a cold water line or conduit is connected to a cold water inlet of the cartridge. The cartridge also includes a mixed water outlet, and a discharge line extends from the water outlet through the spout to provide mixed water for discharge. In operation, an operator actuates the handle to discharge water through the spout at a desired temperature and volume.

Examples of single handle water faucets known in the art are described in U.S. Pat. Nos. 6,155,297, 4,337,795, 4,043,359, 3,965,935, 3,788,354, 3,035,612, 2,977,986, and U.S. Pub. Nos. 2007/0289648 and 2004/0074543. Mixing valve or cartridges known in the art are described in U.S. Pat. Nos. 5,957,160 and 4,979,539.

Conventional single-handle water faucets suffer from a number of limitations that negatively affect their performance, durability and cost of manufacture. For example, some conventional water faucets locate the mixed water outlet in the rear portion of the cartridge. As a result, the discharge line in such faucets assumes an unnecessarily long and circuitous path to the spout that compromises durability and installation of the cartridge in the faucet body. Another disadvantage of conventional water faucets and mixing valves or cartridges is that water lines must be disconnected before the main body of the faucet may be removed for maintenance or replacement.

The present invention is intended to solve these limitations and to provide advantages and aspects not provided by conventional faucet mixing valves or cartridges. A full discussion of the features and advantages of the present invention is deferred to the following detailed description, which proceeds with reference to the accompanying drawings.

SUMMARY OF THE INVENTION

The present invention is directed to an internal assembly for a faucet having an independent base portion, a main body portion, a sealing element, at least one discharge element, a handle that an operator actuates to deliver water at a desired temperature through the discharge element, an annulus, and a radial seal.

According to an aspect of the invention, the main body portion includes a lower disk with a cold water inlet, a hot water inlet, and a mixed water outlet; an intermediate disk with a recessed, arcuate mixing cavity, and a dual lobe sealing element positioned adjacent the lower disk; an upper disk with a central aperture positioned adjacent to the intermediate disk, with at least one engaging member that operably couples it to the intermediate disk; a seat with a central opening positioned adjacent to the upper disk; and a joystick, with a shaft extending through the seat opening and the main body.

The joystick has a depending actuator that is received in the central aperture of the upper disk that operably connects it to the upper disk. Actuation of the joystick results in movement of the upper disk and intermediate disk, varying the position of the mixing cavity relative to the hot and cold water inlets.

According to another aspect of the invention, the independent base is connected to a cold water line and a hot water line, and is mounted to a surface. The main body portion is secured to the independent base with screws, and is removable from the base without disconnecting the water lines.

According to another aspect of the invention, the main body portion has cold and hot water inlet holes, and a mixed water outlet hole so that the mixed water may be discharged directly from the main body through a discharge element. The main body portion may include a change valve, which valve changes the flow of discharged water from one discharge element to another, such as between a spout and a water discharge line connected to the base portion of the assembly.

According to another aspect of the invention, the radial seal is a U-ring, and the main body has an external, arcuate recess and two holes, all for receiving the U-ring.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of the inventive internal assembly for a faucet, showing the various components of the assembly.

FIG. 2 is perspective view of the assembly of FIG. 1, but in an assembled condition.

FIG. 3 is a cutaway view of one embodiment of the invention, including a handle, a cover, and a spout.

FIG. 4 is a bottom view of an intermediate disk of the assembly, with the intermediate disk depicted as having an arcuate mixing cavity and a dual lobe sealing element

FIG. 5. is a bottom, perspective view of the sealing element and lower disk, showing the cold water and hot water inlets, and the mixed water outlet.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 depicts one embodiment of an internal assembly 10 for a faucet of the present invention. The internal assembly 10 includes an independent base 1, a main body 2, a sealing element 3, a lower disk 4, an intermediate disk 5, an upper disk 6, a fixing element 7, a post 8, a joystick 9, a seat 20, an annulus 30, and a retaining U-ring 40.

A cold water inlet 11, a hot water inlet 12 and a water discharge line 13 may be connected to the independent base 1. The sidewall of independent base 1 includes at least one screw hole 14.

The main body 2 includes a cold water inlet hole 21, a hot water inlet hole 22, a mixed water outlet hole 23, a spout discharge hole 25, and optionally, a hole 24 for installing a change valve 60.

The inner wall of the main body 2 includes projections 26. A groove 27 is located around the cold water inlet hole 21, hot water inlet hole 22, and mixed water outlet hole 23. Groove 27 receives sealing element 3.

The top wall of the main body 2 includes an arcuate hole 28 and two small holes 216 for retaining U-ring 40.

The top wall of the main body 2 further includes two arcuate recesses 29, 211 for receiving the seat 20 and the annulus 30. The bottom wall of the main body 2 includes at least one screw hole 212, correspondingly aligned with at least the screw hole 14 on the side of independent base 1, for securing the main body 2 to the independent base 1.

Lower disk 4 includes holes 41, 42 and 43. The holes 41, 42, 43 are communicative with cold water inlet hole 21, hot water inlet hole 22 and mixed water outlet hole 23, respectively. The lower disk 4 also includes notches 44 that receive the projections 26, thereby facilitating securement of the lower disk 4 to the main body 2.

The intermediate disk 5 includes dual lobe sealing element 51 that is slidingly positioned on the lower disk 4. As a result, the intermediate disk 5 is movable along an upper surface 45 of the lower disk 4.

The bottom of the intermediate disk 5 includes a recessed water mixing cavity 53. In addition, the upper disk 6 includes a central aperture 62, and extending engaging members 61.

These engaging members 61 are received within recesses 52 of the intermediate disk 5. The engaging members 61 operably couple the upper disk 6 to the intermediate disk 5.

The upper disk 6 also includes an upwardly directed finger 63 that is received by a recess 203 in the bottom surface of the seat 20. The upwardly directed finger 63 operably couples the upper disk 6 to seat 20.

As may be seen in FIGS. 1 and 2, the seat 20 is positioned adjacent the upper disk 6. The seat 20 has an upwardly extending ring portion 201 having an opening 202 that receives the joystick 9.

Located within seat 20 is a ball surface 204. The ball surface 204 includes a circumferential recess 205 and two symmetrical vertical recesses. The seat 20 also includes projections 207, 208 which engage the arcuate recesses 211, 29 of the main body 2, to secure the seat 20 to the main body 2. Bottom surfaces 209 of the projections 207, 208 abut against the bottom surfaces 215 of the grooves 29,211.

The joystick 9 includes a number of components for operative interaction with the components of the internal assembly 10. As may be seen in FIGS. 1 and 2, the joystick 9 includes an elongated shaft 94 extending through the seat 20, a rotary ball 91, and a depending actuator ball 92 received by the central aperture or opening 62 of the upper disk 6. The post 8 and the fixing element 7, including a flange 71 and an opening 72, receive a portion of the actuator ball 92, and facilitate operable connection of the joystick 9 with the upper disk 6.

Actuation of joystick 9 results in movement of the upper disk 6 and the intermediate disk 5, varying the position of the mixing cavity 53 relative to the cold 11 and hot water inlets 12, and the water outlet 13.

The annulus 30 has a central opening 301 engaging the upwardly extending ring portion 201 of the seat 20. The annulus 30 further includes projections 302, 303 which engage the arcuate recesses 211, 29 of the main body 2, to secure the seat 20 to the main body 2. Projection 302, arcuate recess 211, and projection 207 are sized to ensure a proper fit. Projection 303, arcuate recess 29, and projection 206 are also sized to ensure a proper fit.

The retaining U-ring 40 is inserted into the arcuate hole 28 and the two holes 216, to secure the seat 20 within the main body 2. This further radially seals the main body 2.

FIG. 2 shows the embodiment of FIG. 1, but in an assembled condition. As shown in FIG. 2, a change valve 60 is located in hole 24. Screws 80 are used to secure the main body 2 to the independent base 1. The main body 2 includes circumferential grooves 213, 214. As seen in FIG. 3, these grooves receive a pair of O-rings 50.

FIG. 3 shows an embodiment of the present invention including a spout 70 installed outside of the main body 2. A semi-circular cover 90 is secured to the main body 2. A handle 100 is connected to the joystick 9.

In one embodiment of the invention, an operator actuates the handle 100 and linked joystick assembly 9 to select the temperature and volume of water discharged from the spout. Therefore, actuation of the handle 100 enables the operator to select between an off position (no water discharge), a hot water discharge position, a warm (mixed) water discharge position, and a cold water discharge position.

FIG. 4 is a bottom view of intermediate disk 5, according to one embodiment of the invention. Intermediate disk 5 includes a dual lobe sealing element 51, recessed water mixing cavity 53, and recess 52 for receiving engaging members 61 of upper disk 6. The dual lobe sealing element 51 comprises a stem extending radially inwardly, from the wall of the upper disk, a first lobe extending from the stem, and a second lobe extending from the stem. The recessed water mixing cavity 53 has a generally arcuate configuration. The dual lobe sealing element 51 sealingly engages the hot water inlet and/or the cold water inlet of the lower disk, varying the relative position of the mixing cavity and the mixed water outlet.

FIG. 5 is a bottom view of main body portion 2, according to one embodiment of the invention. The main body portion 2 includes cold water inlet 21, hot water inlet 22, mixed water outlet 23, and groove 27 for receiving sealing element 3.

The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. Accordingly, all suitable modifications and equivalents fall within the scope of the invention. 

1. An internal assembly for a faucet comprising: an independent base portion; a main body portion; a sealing element; at least one discharge element; a handle that an operator actuates to deliver water at a desired temperature through the discharge element; an annulus, and a radial seal; the main body portion including: a lower disk, the lower disk having a cold water inlet, a hot water inlet and a mixed water outlet; an intermediate disk positioned adjacent the lower disk, the intermediate disk having a recessed mixing cavity, and further having a dual lobe sealing element to provide the mixing cavity with an arcuate configuration; an upper disk positioned adjacent to the intermediate disk and having a central aperture and at least one engaging member that operably couples the upper disk to the intermediate disk; a seat positioned adjacent the upper disk, the seat having a central opening; a post and a fixing element, including a flange and an opening, the opening receiving a portion of the actuator ball of a joystick, and facilitating operable connection of the joystick with the upper disk; the joystick further having a shaft extending through the seat opening and through the main body, the joystick further having a depending actuator that is received in the upper disk aperture to operably connect the joystick to the upper disk; wherein actuation of the joystick results in movement of the upper disk and intermediate disk to vary the position of the mixing cavity relative to the hot and cold water inlets.
 2. The internal assembly for a faucet of claim 1, wherein the independent base portion is connected to a cold water line and a hot water line, and is mounted to a surface, wherein the main body portion is secured to the independent base portion by screws, and wherein the main body portion may be removed from the independent base portion without disconnecting the cold water line or the hot water line from the independent base portion.
 3. The internal assembly for a faucet of claim 1, wherein the main body portion has a cold water inlet hole, a hot water inlet hole, and a mixed water outlet hole such that the mixed water may be discharged directly from the main body through at least one of the discharge elements.
 4. The internal assembly for a faucet of claim 3, wherein the discharge elements comprise a spout connected to the main body portion, and a discharge line connected to the independent base portion, wherein the main body portion contains a change valve wherein actuation of the change valve changes the flow of discharged water between the spout and the discharge line.
 5. The internal assembly for a faucet of claim 1, wherein the radial seal comprises a U-ring, and the main body portion has an external arcuate recess and two holes for receiving the U-ring.
 6. The internal assembly for a faucet of claim 1, wherein the seat contains two outward projections and the main body has two internal arcuate recesses for receiving the seat and the annulus to transversely seal the faucet.
 7. The internal assembly for a faucet of claim 1, wherein the discharge elements include a spout and a water outlet line through the independent base portion.
 8. The internal assembly for a faucet of claim 1, wherein actuation of the joystick results in movement of the upper disk and intermediate disk to vary the position of the mixing cavity relative to the hot and cold water inlets and the mixed water outlet.
 9. The internal assembly for a faucet of claim 1, wherein the intermediate disk has a diameter less than a diameter of the lower disk. 